Cupola apparatus and method of melting metal



March 2 8, 1944. H. A. REECE 2,345,502

CUPOLA APPARATUS AND METHOD OF MELTING METAL Filed March 13, 1942 2 Sheets-Sheet 1 INVENTOR.

. Mega/415 505 March 28, 1944. REECE 2,345,502

CUPOLA APPARATUS AND METHOD OF MEL'IING METAL Filed March 13. 1942 2 Sheets-Sheet 2 INVENTOR. Aswan/Q, fife:

Patented Mar. 28, 1944 CUPOLA APPARATUS AND METHOD OF MELTING METAL Herbert A. Reece, Cleveland Heights, Ohio Application March 13, 1942, Serial No. 434,455

13 Claims.

My invention relates to metallurgical furnaces and particularly to cupolas in the foundry art andto'similar devices.

The efllcient and economical operation of a foundry often requires that cupolas of different melting capacity be used at different times in accordance with the requirements of the foundry. Where there is a large sized cupola and the foundry requirements call for a relatively small amount of metal to be melted it is necessary to operate the cupola on the basis of a charge proportioned to a cross-section of the cupola with resulting dilution of charges and excess costs for metal produced.

In the past it has often been the custom to attempt to proportion the cupola in accordance with the amount of material to be processed by rebuilding the walls of the cupola with a thicker lining to decrease the internal diameter of the cupola. This system of re-building the cupola to change its melting capacity in accordance with the amount of metal to be melted has serious disadvantages and limitations. It is necessary to clean out the cupola completely. to cool it, and to re-build the refractory lining of the well or lower portion of the cupola. Such a system is laborious, expensive and time consuming.

Another possible way of meeting the requirements of a foundry is to have a plurality of complete cupolas, each of a different size or melting capacity. The cupola having the desired capacity for the requirements of the foundry at any one time is operated and the other cupolas remain idle. The disadvantages and limitations of this answer to the problem are also apparent. The cost of having a plurality of cupolas available when only one is to be operated is often a prohibitive expense. Likewise, the cost of installing a number of cupolas in such a situation is a burden. An additional objection to having a plurality of cupolas when only one is to be operated is the space required for having a number of complete cupolas all set up for operation. A foundrys conveying system is such that itis most economical and convenient to have the cupola mounted at one central position. Having the cupolas mounted for operation at scattered positions interferes with thhe economical and eflicient distribution of materials to be charged into the cupola and with the distribution of molten metal poured from the cupola. It upsets the normal and routine operations of the foundry to have to charge one cupola at one location and then to change over to charge a cupola at another location. It likewise disturbs the normal and routine procedure of the foundry to pour molten metal at one location and then to change over to pour it at another location. Additions and modifications inethe conveying system for both raw materials and for the molten metal is, necessitated by such a system of plural cupolas mounted at different locations.

It is an object of my invention to obviate the disadvantages, limitations and defects of the prior practices of foundry melting as herein suggested and as otherwise known in the art.

Another object is the provision of a flexible and adequate system for melting of metal in a. cupola with the maximum of efl'iciency and economy.

Another object is the provision of a cupola having replaceable parts of different capacities to meet the requirements of a foundry.

Another object is the provision of a cupola having severable parts for accommodating the substitution of parts having the size and capacity required.

Another object is the provision of a cupola having a stack portion mounted in position and a plurality of well portions movable relative to the stack portions and adapted to be selectively assembled therewith.

Another object is the provision for an improved method of melting operation in a foundry.

Other objects and a fuller understanding of my invention may be had by referring to the following description and claims, taken in conjunction with the accompanying drawings, in which:

Figure 1 is an elevational view of apparatus embodying my invention;

Figure 2 is a longitudinal sectional view of the adjoining portions of the stack and well of the left-hand cupola shown in Figure 1;

Figure 3 is a longitudinal sectional view of the top of the cupola well shown on the right-hand side of Figure 1;

Figure 4 is a transverse sectional view through the line 4-4 of Figure 2;

Figure 5 is a plan view looking. down on the top of the well shown in Figure 3 and in the direction of the arrows 55;

Figure 6 is a cross-sectional view of the appa ratus embodying my invention shown in Figure 1 and taken along the line 6-5 of Figure 1;

Figure 7 is a view looking up at the bottom of a cupola well in my apparatus and is a view in the direction of the arrows 1-1 of Figure 1;

Figure 8 illustrates a modified form of carriage and track wherein intermeshing gears and a rack are utilized; and

that any number of required cupola walls may be I utilized and embodied in my invention. For example, there may be three or four or five wells all of different diameters or different melting capacities. I

The stack ll consists of the upper portion of a usual cupola of hollow cylindrical shape. The stack H or upper portion of the cupola acts as a chimney for carrying 011' the heat and hot gases generated within the cupola and also acts as a conduit through which material is charged into the well or lower portion of the cupola. As in the usual construction, an arrester i4 is positioned above the stack H as shown and charging doors l5 provide an entrance through the wall of the stack for the charging of material to the interior of the cupola.

The stack i l extends through an appropriate opening in the charging floor 2i and is supported thereon by a suitable flange mounting 38 connecting the stack II to the charging floor 2i. The walls of the stack Ii extend downwardly to, or slightly below, the level of the charging floor 2i. It is seen from the drawings, that the stack or upper portion of the cupola is suspended at an elevated position with its open bottom end disposed at or below the elevated charging floor 2 I.

The well or bottom portion l2 which is positioned below the stack II in Figure 1 has the usual construction of the lower portion of an operative cupola. A wind box Hi mounted on the side of the well or lower portion i2 is adapted to supply a blast of air from the blast main i! into the interior of the cupola through the tuyeres (not shown), the blast main l'l being in communication with a source of air supply, such as a blower, not shown in the drawings. The inlet pipe is as shown in dotted lines in Figure 1 and in full lines in Figure 6 provides communication between the blast main i1 and the wind box It.

On the front side of the cupola well and near the lower portion thereof is positioned the spout mounting means iii to which is attached the spout 20 for the discharge of molten metal upon the tapping of the cupola. Upon the opposite side or rear of the cupola and at an elevation above the metal spout 20 is located the slag spout 45 shown in the view of Figure 6.

The well I2 is mounted upon a carriage 39 having the four wheels 40. A track ll having suitable channeled runways is supported at an elevation by the column supports 42 above the foundation or, floor 43, the floor 43 being the pouring floor of the foundry where the pouring operations take place. Suitable stops 44 are provided on the track ll to limit the movement of the carriage 39 along the track ll beyond the extent desired.

. The well i2 is distinct and separable from the stack ll. Upon the movement of the well l2 along the track I to the position shown in Figure 1, the well l2 substantially registers with the stack II. To close the clearance space between the well l2 and stack ii and to provide a joinder asaasoa between the two parts a telescoping ring or cylinder 22 is provided at the juncture or division between the stack is and well H2. The telescoping ring 2215 mounted to two rods N by means of the extensions or ears 23. The rods 26 extend up through openings in the charging floor 2| and may be pulled up or moved down by manual operation from the charging floor. To hold the weight of the ring 22 when the rods are moved to upward position the catches 25 are adapted to engage in the notches 26. The catches 25 may be released in the usual manner to permit the rods 24 to move downwardly when lowering the telescoping ring 22. A stationary ring 21 welded or otherwise secured to the upper portion of the well i2 is adapted to sealingly engage the telescoping ring 22 when lowered and to support the telescoping ring 22 when in the position of Figures 1 and 2. The detailed operation and structure of the parts at the location of the joinder between stack II and well i2 is shown in detail in Figure 2.

The stack ii is lined in the usual manner with a relatively thin refractory lining 28 composed of a layer of firebrick. The refractory lining 28 is supported in position by a supporting flange or ring 29 or by any other suitable means such as studs extending into the refractory lining.

A refractory lining 32 for the well I! is relatively thick as compared to the refractory lining 28 as the melting and generation of heat occurs in the well or lower portion of the cupola, the stack Ii merely carrying of! the hot gases generated below. An iron charging ring 3! positioned upon the top of the thick refractory lining 32 forms a ledge or shelf over the thicker lining and protects the lining 32 from damage by the material charged down into the well I2 from the charging door IS. The charging ring 3! may be of one integral piece or may be made up of a plurality of segments. As seen from Figure 2, the charging ring 3! is at the upper edge of the walls of the well I2. To better seal the joint between the stack II and well i2, daubing 30 of plastic refractory material, such as fireclay, is plastered between the charging ring 3i and the lower edge of the refractory lining of the stack. The daubing 30 is placed in position after the stack Ii and well I: are in alignment to the position shown in Figure 2 and may be applied by throwing handfuls of daubing through the charging door i5 down upon the charging ring 3| into the crevice or clearance space or may be otherwise applied by suitable means.

The left-hand half of Figure 1, the view of Figure 2 and the view of Figure 4 discloses that a complete operative cupola having all of the necessary parts for the usual operation of the same is provided. It is to be understood that this cupola has all of the parts necessary for successful and continued operation of the same. For purposes of simplicity of illustration it has been considered as unnecessary to show such features as the clean-out door, peep-holes, a blower and such other features as are usually associated with a complete cupola.

The well or lower portion l3 shown on the right-hand side of the views of Figures 1 and 6 and in Figures 3, 5 and 7, is substantially similar in construction to the well l2 previously described. However, the well it is of smaller diameter, both internally and externally, than the well i2. The capacity of the well [3 for material charged therein is substantially smaller than that of the well l2. Preferably the wind box on the well I! is proportionately smaller and is adapted to accommodate the requirements of the well H. The inlet i8 is the same on both wind boxes so as to permit universal connection with the blast main II.

The upper edge portions of wells l2 and I: are of substantially the same diameter and to provide for this the diameter of the smaller well I3 is expanded at location 35 to flange out as shown on the right-hand side of Figure 1. By means of the flare IS, the upper edge portion of the well I3 is adapted to register with the stack Ii as the stack II is of a size adapted to accommodate the larger diameter well It.

The internal structure of the well I! at the upper edge portion thereof is somewhat modified from that of the larger size well I! in order to provide for the differential in diameters between the top edge portion of the well l3 and the body portion of the well l3. In the well l3 9. modified form of charging ring 38 is mounted in position as shown in Figures 3 and 5. The refractory lining 34 of the well I! is protected by the charging ring 33. The diameter within the refractory lining 34 is smaller than the diameter within the refractory lining 32 of the well l2. A ring or course or firebrick or iron block 35 is'positioned upon the top of the charging ring 33 as shown in Figure 3. The top edge of the well l3 as formed by the course 35 of bricks or blocks is adapted to mate with or substantially register with the lower edge portion of the stack I I.

To permit either inlet pipe I8 of the respective wells I 2 and I3 to be connected with the blast main H a movable connection 31 is provided on the end of the blast main I! as shown in Figure 6. By moving the connecting sleeve 31 back on the, blast main H the inlet iii of one well may be disconnected and upon movement of another well to the same position the inlet pipe of the substituted well may be connected to the blast main II. Suitable gaskets are provided at the joints of the connection 31, the blast main I1 and the inlet pipes l8.

Figure 7 being a view in the direction of the arrows 1-1 of Figure 1, shows the bottom of the well l3 and the mounting of its carriage 38 on the track M. It also illustrates the drop-bottom doors 46 provided for cleaning out the interior of the well l3. Well I2 and any other cupola wells utilized have a similar drop-bottom door and appear substantially similar to that of Figure 7 from a view looking up at the bottom thereof.

From the views of the drawings and the foregoing description it is seen that either well I! or well I 3 may be used in conjunction with the stack H. The stack II is of a diameter and capacity suiiicient to meet the requirements of the largest of the cupola wells used, and thus is sufficient to carry on the hot gases of the larger size cupola wells and to provide a conduit for the charging of material into the largest of the cupola wells. In the event that the requirements of the foundry suggest the desirability of using the smaller size cupola well l3 then the well I! is disconnected by raising the telescoping ring 22 by means of the rods 24 and the blast main I1 is disconnected by means of the adjustable connection 31, and the spout 20 is removed. The well I2 is then rolled along the track 4! upon its carriage 39 to one side away from the stack l I. The smaller size well I3 is then rolled along the track 4| to the position previously occupied by the well l2 under the stack II. The telescoping ring 22 is lowered to join the stack II and well It and daubing may be applied as required or desired. The blast main I1 is then placed in communication with the wind box oi. the well I; through its respective inlet pipe ll. The spout 20 is then mounted in pouring position to the well II. The substituted well II and stack N then form a complete and operative cupola having a melting capacity meeting the present requirements of the foundry. It is understood, of course, that other wells of varying diameter and capacity may be used in my apparatus, only two wells 12 and It being shown in the views of the drawings for purposes of simplicity in illustration.

It is to be noted that the cupola well out of I operation and standing at one side may be readily cooled and daubing or patching placed therein during the repair of the lining may be readily dried by reason of the free circualtion of air through the interior or the well up through the opened drop-bottom door and through the open top of the disconnected well. This feature is a great advantage in the repair and rebuilding oi the cupola lining, particularly of the bumout in the lining, and greatly facilitates keeping the cupola in operation without undue loss of time.

While only a straight section of track 4| is shown in the drawings, it is to be understood that this track 4| includes sufficient length for moving the cupola wells around as desired and includes Ys or other configuration necessary for the desired switching of the cupola wells around in desired locations. Likewise, a turntable or any other suitable arrangement may be used for facilitating the movement of one well into position and the moving of the other well out of position in assembling a cupola of desired capacity.

Figure 8 illustrates a modified arrangement for moving the respective wells about as desired. In this modified arrangement gear wheels 41 are substituted for the round wheels 40 and the rack 48 is substituted for the smooth bottomed track 4|. A crank handle 49 may be applied to the axle of the gear wheel 41 to move the carriage 39 along the rack 48 and to thus move the respective cupola well forward or backward relative to the stack I I.

Figure 9 illustrates diagrammatically a modified arrangement for moving a plurality of cupola wells of difierent diameters relative to a cupola of the cupola wells which is cupola well D. In

the illustration of Figure 9, cupola well C is registered with and joined with the cupola stack D and with it forms a complete operative cupola. The cupola wells A, B and D are idle and are positioned back away from the stack D where the melting operation takes place. The cupola wells A, B, C and D may be independently rolled around on the track XY or may be Joined together in spaced relationship in which .case the track XY is a turntable upon which the cupola wells revolve. Y

My invention includes the method 01' operating a foundry wherein a cupola stack is utilized for selective combination with a plurality oi. cupola wells of difl'erent capacity as herein described. My invention also includes the method oi, and apparatus for, mounting a complete cupola on a carriage movable on a runway, on a cupola or on other suitable moving means to utilize one tapping and pouring location in the foundry. The present specification includes the foregoing description taken in conjunction with the views of the drawings as well as the description of my invention as contained in the annexed claims which are made a part of this specification by reference thereto.

Although I have described my invention with a certain degree of particularity, it is understood that the present disclosure has been made only by way of example and that numerous changes in the details of construction and the combination and arrangement of parts may be resorted to without departing from the spirit and the scope of the invention as hereinafter claimed.

I claim as my invention:

1. In a foundry metal melting system, a unit comprising the combination of a plurality of cupola wells having different sized diameters for meeting difierent metal melting requirements of the foundry, a cupola stack having a diameter sufficient to provide an adequate outlet for hot gases from the larger diameter size of said wells, said cupola stack having an open bottom and being mounted at an elevated position to permit either of said wells to be positioned below the open bottom of said stack, there being a clearance space between the bottom of the stack and the top of said either well to permit sideward movement of the well relative to the stack, each of said wells having an open top adapted to register with the open bottom of said stack, a common support for said wells, said common support being disposed on one horizontal plane, carriage means connecting said wells and said support to permit movement of said wells along said horizontal plane for interchange of said wells relative to said stack, and movable closure means suspended downwardly from said stack for closing said clearance space upon registration of either of said wells with said stack and for opening said clearance space upon sideward movement of said either well relative to the stack the arrangement of the stack, the plurality of wells, the support and the carriage means providing for the ready assembly of a stack and well cupola structure of required metal melting capacity.

2. A metal melting system for a foundry having different operating requirements wherein the respective capacities of different diameter cupolas are required for said requirements. comprising, in combination, a unit consisting of a plurality of cupola wells of different diameters for accommodating different amounts of material therein but all having top members of the same diameter, a cupola stack having a diameter sufficient to meet the requirements of the larger of said cupola wells, said cupola stack being mountable at a fixed elevated position, movable mounting means disposed on a fixed horizontal plane below said stack for said plurality of wells to permit a selected well to be moved along said plane and under said stack and in alignment therewith to provide a cupola, and joining means extensible downwardly from said stack for joining the stack and said selected well.

3. In a metal melting system for a foundry requiring different melting capacities at different times, a cupola structure having interchangeable parts for meeting said different requirements, said cupola structure comprising a stack portion mounted at an elevation and in fixed position, a unit comprising a plurality of well portions having different melting capacities, respectively, a support disposed on a horizontal plane for said well portions, means for moving said well portions along said support laterally of said stack portion to selectively position one of said well portions under, and in juxtaposition to, said stack portion, and movable connecting means adapted to extend downwardly from said stack portion toward said selected well for joining said stack portion and said selected well portion maintained on said horizontal plane to complete said cupola structure without vertical movement of said selected well portion, the completed cupola structure being assembled to meet the melting requirement of the foundry. 1

fl. The combination of a cupola stack of a fixed dimension, a unit comprising a plurality of cupola wells of different dimensions disposed on one horizontal plane each provided with an open top designed for interfitting-with said cupola stack, the dimension of the stack being suflicient to accommodate the requirements of the largest of said wells, and carrying means for moving said wells relative to, and laterally of, said stack on said horizontal plane to provide for the selective joinder of a well of required dimension while on said horizontal plane, of said plurality of wells, to said stack in accordance with the melting capacity desired.

5.. In a metal melting system of a foundry, a cupola having a stack portion and a unit comprising a plurality of well portions, said well portions being disposed along a horizontal plane below said stack portion, the stack portion having a bottom opening, and each 01' the well portions having a top opening adapted to register upon positioning a selected well portion immediately below the said stack portion to form a complete cupola, said well portions having different capacities to meet different melting requirements of'the furnace and said stack portion having a capacity to serve the larger of said well portions, means for moving said Well portions laterally of said stack portion along said horizontal plane to provide for ready replacement of one of said well portions with another of said well portions without vertical movement 03 said selected well portion, and telescoping means extensible downwardly from the stack portion toward the said selected well portion for connecting said stack portion to the said selected well portion placed beneath said stack portion.

6. A cupola having a stack portion and a well portion separated from each other, said stack portion being mounted independently of said well portion, said stack portion having a charging door and said well portion having a wind box and being adapted to receive substantially all of he material charged into said cupola through said door, carriage means for movably supporting said well portion to permit it to be moved laterally of the stack portion and toward and away from said stack portion, and adjustable connecting means surrounding the bottom of the stack portion and adapted to telescope the top of said well portion for joining said stack portion and said well portion to permit said stack portion and well portion to be selectively joined and dis-joined without vertical movement of the well portion, the arrangement of stack portion, well portion, carriage means and connecting means providing for the ready substitution of another well portion for said well portion in said cupola.

7. A cupola having a stack portion and a well portion adapted to receive substantially all of the material charged into the cupola, a movable intermediate portion adapted to telescopically embrace the bottom of the stack portion and the top of the well portion for facilitating ready joinder and severence of the said stack portion and well portion, and a movable carriage for said well portion for facilitating ready movement of the well portion laterally of the stack portion and toward and away from said stack portion to provide for the assembling and dis-assembling of the stack portion and well portion without vertical movement of the well portion.

8. A cupola having a vertically movable severable intermediate portion embracing the lower portion and upper portion of the cupola to permit separation of the lower portion relative to the upper portion of the cupola and having a movable base to permit lateral movement of the lower portion relative to upper portion upon vertical movement of said intermediate portion whereby said lower portion may be replaced by another lower portion moved directly lateral of said upper portion, said lower portion being adapted to receive substantially all of the material with which the cupola is charged.

9. In a foundry having a charging floor on one level and a pouring floor on a second level below said one level and having a blast main, the combination of an upper portion of a cupola forming the stack and charging conduit of said cupola, said upper portion being mounted to said charging floor, a unit comprising a plurality of lower portions for said cupola, each said lower portion forming a well for the melting of metal and a wind box for the distribution of an air blast to the well, said wells having different sized internal diameters to accommodate different amounts of material therein, a track positioned intermediate, and parallel to, said charging floor and said pouring floor, wheeled carriages for each of said lower cupola portions movable along said track to permit movement of the said lower cupola portions under said charging floor laterally of the upper cupola portion to and from a position under said upper cupola portion, a movable connection adapted to provide communication between said blast main and the wind box of the lower cupola portion positioned below said upper cupola portion, and a movable Joining member carried by said charging floor and adapted tosurround and telescopically join the upper cupola portion to the lower cupola portion positioned below said upper cupola portion, the combination of upper cupola portion, lower cupola portio track, carriages, movable connection, and movable joinin member providing for the portion of selected capacity to the upper cupola portion to provide an operative cupola of required size in communication with said blast main.

10. In a foundry having a charging floor on one level and a pouring floor on a second level below said one level and having a blast main, the combination of an upper portion of a cupola forming the stack and charging conduit of said cupola, said upper portion being mounted to said charging floor, a lower portion for said cupola forming a well for the melting of metal and a wind box for the distribution of an air blast to the well, a track positioned intermediate, and parallel to, said charging floor and said pouring floor, a wheeled carriage for said lower cupola portion movable along said track to permit movement of the said lower cupola portion under said charging floor laterally of the upper cupola portion to and from a position under said upper cupolaportion, a movable connection adapted to provide communication between said blast main and the wind box of the lower cupola portion when positioned below said upper cupola portion, and a movable joining member carried by. said charging floor and adapted to surround and telescopically join the upper cupola portion to said lower cupola portion, the combination of upper cupola portion, lower cupola portion, track, carriage, movable connection, and movable joining member providing for the ready assembly and dis-assembly of a complete cupola to provide as required an operative cupola in communication with said blast main.

11. A cupola comprising an upper section having a charging door and adapted to carry of! hot gases generated in the operation of the cupola, a lower section having a wind box and adapted to receive substantially all of the material charged into the cupola through said charging door, fixed support for said upper section, means for supporting said lower section for movement in a hori zontal direction, and means for detachably connecting said sections together;

12. A cupola comprising an upper section adapted to carry off hot gases generated in the operation of the cupola, a lower section adapted to contain substantially the entire charge of the cupola, separate supports for said upper and lower section. one or said sections being movable horizontally with respect to the other, and means for detachably connecting said sections together. 13. A cupola comprising an. upper section adapted to carry cit hot gases generated in the operation of the cupola, a unit comprising a plurality of lower sections having diflerent melting assembling of a lower cupola capacities, each section being arranged for selective vertical alignment with the upper section, a first support for the upper section, a second support for the lower sections, one oi said supports being movable horizontally with respect to the other to vertically align a lower section with the upper section to make a complete cupola with the lower aligned section adapted to contain substantially the entire charge of the cupola, and a movable interconnecting means for interconnecting a vertically aligned lower section and the upper section. said movable interconnecting means being adapted to fit all of the lower sectio HERBERT A. REECE. 

